Method of assembling electrical terminals on a card



Sept. 7, 1965 F. A. KLASEK 3,204,328

METHOD OF ASSEMBLING ELECTRICAL TERMINALS ON A CARD Filed Sept. 1. 1961 2 Sheets-Sheet 1 INVEWTOR F. AJQA SEA A TTO R/VEV F. A. KLASEK Sept. 7, 1965 METHOD OF ASSEMBLING ELECTRICAL TERMINALS ON A CARD Filed Sept. 1. 1961 2 Sheets-Sheet 2 INVENTOR E A. KLA 55/1 BY Q a ATTOR 5y United States Patent METHOD The present invention pertains to methods of assembling articles, and more particularly to methods of attaching electrical terminals to insulators.

An object of the invention is to provide an efficient method of assembling a group of electrical terminals simultaneously to an insulator card.

A further object of the invention is to provide a method of attaching a group of electrical terminals in an arcuate array to an arcuately shaped insulator card.

In accordance with the above objects, one embodiment of the invention contemplates the provision of an apparatus and method for attaching electrical terminals to cards or sheets of insulating material, in which the terminals are attached to the cards in groups after fanning out a predetermined number of terminals from a continuous strip of interconnected terminals, 'the assembled groups being intermittently advanced through a curved or arcuate guide slot to a superposed position over a previously dial fed arcuate shaped insulator card to which the predetermined group of terminals are attached simultaneously by means of punch and die members by drawing eyelets around previously punched holes in the terminals, and simultaneously pressing the eyelets into the cards to attach the terminals to the cards.

Other features and advantages of the invention will become apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic view of the arrangement according to the present invention;

FIG. 2 is a plan view of the machine for assembling the product according to the invention;

FIGS. 3 and 4 are enlarged detail sections of the punch and die members;

FIG. 5 is a sectional view taken substantially on line 5-5 of FIG. 2;

FIG. 6 is a view of the drive mechanism for the apparatus shown in FIGS. 2 and 5;

FIG. 7 is a plan view of an insulator card having a plurality of terminals attached thereto by the method and apparatus of the present invention, and

FIG. 8 is a perspective view of a section of a strip of interconnected terminals preparatory to the assembly operation.

Referring now to the drawings, there is illustrated in FIG. 7 an arcuate shaped sheet or card 11 of insulating mate-rial having a plurality of electrical terminals 12 attached thereto by the method and apparatus of the present invention. The terminals are arranged radially of the insulator card and each terminal is attached to the card by means of two tubular eyelets 13 which are formed integral with the terminal, as will hereinafter appear, which extend into the insulating card 11, as shown in FIG. 4. A plurality of these so-called terminal cards may 'be stacked and assembled in the usual manner to form banks of terminals in stepping switches, such as are employed in telephone systems.

Having reference to FIG. 1 there is shown schematically the arrangement of the terminal strip forming apparatus 14 and a pair of assembly presses 15 and 16. In forming the terminal strip 17, a section of which is shown in perspective view in FIG. 8, a ribbon or strip 18 of sheet brass or other suitable conducting material, is fed into the forming apparatus 14, wherein the strip 13 is separated into two parts 17, and each part is formed with a turned up edge or flange 19 and a series of interconnected terminals 12 formed integral with the pilot flange 19 substantially as shown in FIG. 8. The terminals 12 are constricted along a line 22 to facilitate the shearing operation as will hereinafter be described. Also, the flange 19 is suitably notched at predetermined points to facilitate feeding the strip or part 17 into the respective assembling press 15 or 16, as will presently appear.

As shown in FIG. 2, the terminal strip 17 is fed into the assembling press 15 and is caused to be fanned out, in a manner to be presently described, so that the terminals 12 may ultimately be attached to a card 11 at an assembly station 100.

Referring to FIGS. 2 and 5, the assembly press 15 comprises a vertical shaft 24 suitably journalled in the stationary bed 25.

Keyed to the shaft 24 is a pinion 26 which meshes with a rack 27 (FIGS. 5 and 6). Encircling the shaft 24 in juxtaposition with the pinion 26 is a sleeve 28 to which is keyed a pinion 29 which meshes with a rack 31. Racks 27 and 31 are secured to a block 32 to which is attached one end of a plunger or ram 33 to which power is applied, in any well-known manner, to reciprocate racks 27 and 31 to impart rotation in opposite directions, respectively, to shaft 24 and sleeve 28.

Pinion 29 is formed from a sleeve portion 34 which terminates in an arm 35 integral thereto (FIGS. 2 and 5). Arm 35 is provided at its free end with an arcuate portion 36 which is concentric with the sleeve portion 34, and is traversable over the bed portion 37 of the assembly press 15 to deliver cards 11 to the assembly station 100, as will presently be described.

Keyed to the shaft 24 adjacent its upper end is a disc member 38 in which a double-toothed pawl 39 is pivotally mounted. As shown in FIG. 2, pawl 39 is normally urged in a clockwise direction about its pivot 41 by a spring 42 to cause the teeth of the pawl 39' to engage suitable notches 43 (FIG. 8) in the flange 19 of the terminal strip 17.

The upper end of shaft 24 is reduced in diameter to receive a cap member 44 which is disposed between the shoulder 45 and a cap nut 46. The cap member 44 is held against rotation by a dowel pin 48 (FIG. 2) and is provided with an integral, downwardly directed flange 49 (FIGS. 2 and 5) spaced from the periphery of the member 38 to provide a curved groove or guideway at the assembly station for the passage of the flange 19 therethrough, as will presently appear.

In juxtaposition with the flange 49 of the cap member 44 is a combination punch and shear member 51 secured in the usual manner to a reciprocable ram (not shown) of the assembly press 15. In the embodiment of the invention shown, it is contemplated to attach ten terminals 12 simultaneoulsy to the card 11 (FIG. 7), and therefore, the member 51 is provided with ten pairs of vertical bores 52 adapted to slidably receive a corresponding number of pairs of drawing punches 53. For example, the combination punch and shear member 51 may be of a construction exemplified by FIG. 3 of U.S. Patent No. 2,394,837, wherein the shearing portion and the punch portion are cooperatively related by spring loaded bolts (analogous to bolts 38 and springs 42 of the patent), and the punches 53 are carried in a punch supporting plate secured to the reciprocating ram of the assembly press, substantially as shown in the patent.

Cooperating with the combination punch and shear member 51 is a substantially U-shaped support 54 for the terminal strip 17 as the flange 19 of strip 17 is threaded through the groove provided therefor between flange 49 and disc 38. Nested in the U-shaped support 54 and fixedly supported on posts 57 secured in the press 15 is the stationary receiving die holder 55 having a bed surface 56 co-extensive with the bed surface of arm 37 whereby the card 11 is readily transferred, as will presently appear, from the card feeding position to the assembly station 100.

Carried in the die holder 55 in properly aligned posi-' tions with respect to the punches 53 are a corresponding number of dies 58. Although the die holder 55 is held in a stationary position by posts 57, the support 54 is movable reciprocatively with respect therewith, and is normally held in its uppermost position by a compression spring 59 acting on a plunger 61 integral with the support 54, the plunger 61 having a movement-limiting knob 62. Coacting with the shearing edge 63 of the combination punch and shear member 51 is a companion shear member 64 appropriately positioned and fixed in the assembly press 15. In the embodiment of the invention shown in the drawings, spring-loaded ball-type detent devices 65 are provided in the card feed and the card assembly positions to hold the card 11 against displacement during the transfer operation by cooperating with appropriately located apertures 66 in cards 11. Moreover, the bed portion 37 is recessed slightly at 67 (FIG. 2) to provide a curved ledge to further guide the card 11. Cards 11 and terminals 12 are prepunched with pairs of holes 68 and 69, respectively, adapted to be presented coincidentally with the punches 53 and dies 58, as will presently appear, to effectuate the eyeletting operation.

In the operation of the arrangement according to the present invention, the condition precedent to the effectuation of the assembly of the terminals 12 to the cards 11 is the timed presentment of the desired number of fanned out terminals 12 and an insulator card 11 under the punches 53. The cards 11 may be fed, either manually or automatically, to the position under the arcuate portion 36 shown in FIG. 2 so that the detents 65 coact with holes 66, and the edge 71 of the card 11 is in abuttting relation with a pair of pins or studs 72 attached to the portion 36. Simultaneously, the terminal strip 17 is presented to the groove provided between the flange 49 and the periphery of member 38 so that the notches 43 engage the teeth on the pawl 39.

The power is then applied to initiate the movement of the plunger or ram 33, whereupon the racks 27 and 31 cause the pinions 26 and 29 respectively, to rotate simultaneously in opposite directions. The rotation of pinion 26 in a counterclockwise direction (as viewed in FIG. 2) causes the pawl 39 to draw the flange 19 of the terminal strip through a predetermined distance along the aforementioned curved groove, whereby a group of a prescribed number of the terminals 12 (ten in number in the present embodiment are advanced into the assembly station 100) are fanned out into an arcuate array in a predetermined diverging relation to one another to coin-. cide with the angular positions of the punches 53. The rotation of pinion 29 in a clockwise direction (as viewed in FIG. 2) causes the studs 72 to push the card 11 around (guided by ledge 67) into the assembly station 100 whereat the detents 65 coact with the holes 66 to hold the card 11 in a position so that the holes 68 therein coincide with the holes 69 in the terminals 12, and with the punches 53.

The ram 33 is then withdrawn, or returned in its reciprocative motion, whereby reverse rotations are imparted, respectively, to the pinions 26 and 29. Accordingly, pawl 39 is returned in a clockwise direction to the position shown in FIG. 2. The terminal strip 17, however, is not moved because the pawl 39 merely slides over or along the notches 43 in flange 19, the curvature of the pilot flange 19 offering sufficient resistance to movement to prevent reverse movement. Upon the return of pawl 39' to the positionshown in FIG. 2, the

4 teeth thereof engage a new pair of notches 43 preparatory to feed the bendable terminal strip 17 in the succeeding assembly operatiom' Simultaneously the portion 36 is returned to its position shown in FIG. 2, preparatory to the feeding of a new card 11 in the succeeding operation.

After the pawl 39 and arm 36 have been returned, the combination punch and shear member 51 is reciprocated in well known manner to effect the eyeletting operation. On the downward stroke of the member 51, the opposite end portion of the terminals 12 which extend beyond the vertically projected area of the card 11 are clamped between the member 51 and the member 54 to hold the terminals in fixed relation to one another and substantially simultaneously therewith or slightly in advance thereof the tapered ends of the punches 53 engage the holes 69 of the terminals 12 and eventually engage the holes 63 of the cards 11 to thereby align the holes accurately for the eyeletting operation. Pursuant to further downward movement of the member 51, the member 54 is depressed against the action of the spring 59 and the shearing edge 63 of the member 51 coacts with the companion shear member 64 to shear-off or sever the terminals 12 from the terminal strip 17, the terminals of the group of severed terminals being held in fixed relation to one another between the members 51 and 54. Upon further downward movement of member 51 the terminals are carried into engagement with the card 11 and the tapered ends of punches 53 engage the holes 68 of the card 11 as shown in FIG. 3. Upon still further downward movement of the member 51, the tapered ends of punches 53 cause tubular eyelets 13 to be drawn from the metal surrounding the holes in the terminals 12, and to enfold the card 11 around the perimeter of the holes in the manner substantially as shown in FIG. 4 to form eyelets. In other words, the tapered ends of the punches 53 extrude tubular projections out of the terminals 12 into gripping engagement with the walls of the perforations in the insulator card 11.

Upon the upward or return movement of the ram of the machine 15, the card 11 with the terminals 12 eyeletted thereto is raised by the U-shaped member 54 under the influence of spring 59 to the level 73 shown in FIG. 5 whereupon the assembled card 11 and terminals 12 is ejected in any well known manner. The flange 19 with integral stubs 74 continues on through the aforementioned groove or guideway provided. therefor during the succeeding operations to be disposed of as scrap in any suitable manner.

The invention herein described embraces the process of forming a fanned-out array from a group of originally parallel members 12 which extend outward from a bendable strip 17 that interconnects all of the members by an inner edge of the strip (FIG. 8), which process comprises the steps of bending the continuous edge of the strip at right angles to itself to provide a pilot flange 19 running the length of the strip, and advancing the pilot flange 19 through the arcuate guide slot provided between flange 49 and disc 38 to a rest position where the flange 19 is bent into a curve that conforms to the guide slot, which operation causes the individual members 12 extending from the strip 17 to fanout into an arcuate array where the free ends of the members are spaced at predetermined angles based on the radius of curvature of the guide slot.

It is to be understood that the invention is not limited to the particular embodiments thereof herein illustrated and described, but is capable of other applications within the scope of the appended claims.

What is claimed is:

1. A method of attaching a group of terminals onto an arcuate card with the terminals arranged on the card in an arcuate array which comprises:

forming an elongated row of flat terminals in parallel relation to one another from a metal strip and with each of the terminals attached at one end to a straight pilot flange disposed at right angles to the terminals;

advancing an arcuate card to an assembly station with the card disposed on a plane and concentric with an axis perpendicular to the plane;

advancing the pilot flange of the row of terminals longitudinally a predetermined distance toward the assembly station parallel to the plane and in spaced relation thereto and directing a portion of the flange along a curved path at the assembly station to advance a group of a prescribed number of the terminals into the assembly station and to bend a portion of the pilot flange into an arc concentric With said axis and cause the terminals of the group to be moved laterally from one another into an arcuate array in a preselected spaced and diverging relation to one another and to a predetermined position in opposed, aligned, and parallel relation to the card and with the opposite end portions of the terminals disposed beyond the projected area of the card;

gripping the opposite end portions of the group of terminals beyond the projected area of the card to hold the terminals in fixed relation to one another;

severing the group of terminals from the pilot flange;

moving the group of severed terminals in fixed relation to each other into a predetermined position on the card; and

securing the severed terminals to the card.

2. A method of attaching groups of terminals onto arcuate cards With the terminals arranged on each card in an arcuate array which comprises:

forming an elongated row of flat terminals in parallel relation to one another from a metal strip and with each of the terminals attached at one end to a straight pilot flange disposed at right angles to the terminals;

advancing successive arcuate cards to an assembly station with the card disposed on a horizontal plane and concentric With a vertical axis;

advancing the pilot flange of the row of terminals longitudinally thereof a predetermined distance toward the assembly station parallel to and above the horizontal plane in timed relation to the advancement of the cards and directing a portion of the flange along a curved path at the assembly station to advance a group of a prescribed number of terminals into the assembly station and to bend a portion of the pilot flange into an arc concentric with said axis and cause the terminals of the group to be moved laterally from one another into an arcuate array in a preselected spaced and diverging relation to one another and to a predetermined position in opposed, aligned, and parallel relation to the card and with the opposite end portions of the terminals disposed beyond the projected area of the card;

gripping the opposite end portions of the terminals of successive groups to hold the terminals of each group in fixed relation to one another;

shearing off successive groups of terminals adjacent to the pilot flange;

moving successive groups of sheared olf terminals into a predetermined position on successive cards; and

securing the groups of sheared off terminals to the cards.

References Cited by the Examiner UNITED STATES PATENTS 1,920,154 7/33 Carlson 29155.57 1,920,354 8/33 Carpenter 29l55.57 X 2,340,448 2/44 Andren 2933 2,394,837 2/46 Bartelheim et a1. 29-33 2,441,181 5/48 Bartelheim 29155.55 2,538,950 1/51 Schryber 15364.5 2,835,959 5/58 Martines 29--155.55 2,902,666 9/59 Novajovsky 29-155.55 3,056,195 10/62 Hack 29501 X FOREIGN PATENTS 897,395 11/5 3 Germany. 924,270 4/63 Great Britain.

WHITMORE A. WILTZ, Primary Examiner.

CHARLES W. LANHAM, JOHN F. CAMPBELL,

Examiners. 

1. A METHOD OF ATTACHING A GROUP OF TERMINALS ONTO AN ARCUATE CARD WITH THE TERMINALS ARRANGED ON THE CARD IN AN ARCUATE ARRAY WHICH COMPRISES: FORMING AN ELONGATED ROW OF FLAT TERMINALS IN PARALLEL RELATION TO ONE ANOTHER FROM A METAL STRIP AND WITH EACH OF THE TERMINALS ATTACHED AT ONE END TO A STRAIGHT PILOT FLANGE DISPOSED AT RIGHT ANGLES TO THE TERMINALS; ADVANCING AN ARCUATE CARD TO AN ASSEMBLY STATION WITH THE CARD DISPOSED ON A PLANE AND CONCENTRIC WITH AN AXIS PERPENDICULAR TO THE PLANE; 